THE CANSOLV SO 2 - CO 2 CAPTURE PROCESS

Transcription

1 THE CANSOLV SO 2 - CO 2 CAPTURE PROCESS Carbon Capture Workshop Texas A&M University, Qatar April 2-3, 2012 Niels Fabricius Qatar Shell Copyright of Royal Dutch Shell plc April 2011

2 Presentation Outline Cansolv Technologies and Commercial Experience Demonstration Plant Development of New Solvents for CO2 Capture Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

3 Cansolv Technologies Inc at a Glance Founded in 1997 as Union Carbide spin-off Acquired by Shell Global Solutions November 2008 Located in Montreal, Canada and Bejing, P.R.C. Cansolv commercializes design packages : o Proprietary amine-based scrubbing o Regenerable SO 2 control technology o Regenerable CO 2 capture technology Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

4 Cansolv Experience in SO2 Operating in many industrial applications Spent Acid Regen Tail Gas 36 MMSCFD SRU Tail Gas 16 MMSCFD Batch Lead Smelting 30 MMSCFD FCCU Regen Gas 620 MMSCFD Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

5 14 Cansolv SO2 Plants in Operation Worldwide APPLICATION LOCATION GAS FLOW (Nm3/h) INLET SO2 FINAL EMISSIONS (ppmv) START-UP DATE Sulfur Recovery unit Belgium 12,000 1% Sulfur Recovery unit USA 20,000 4% < Sulfur Recovery unit Canada 18,000 2% 2009 Fluid Catalytic Cracking unit USA 740, ppmv Fluid Coker USA 430, % Zinc Smelter Canada 4,000 7% 10% Lead Smelter India 35, % 11% Lead Smelter China 30, % 10% 2009 Copper Smelter China 40, % 2% 2007 Coal-Fired Cogen Boiler China 960, % < Sulfuric Acid plant USA 40, % < Sulfuric Acid plant China 35, % 2009 Spent catalyst Canada 50, % 2007 Acid Plant Tail Gas USA 157, % < Large Amine plants operating in oxidative environments Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

6 CO2 Capture Piloting Campaigns Application Date Site CO 2 in the gas Removal Natural Gas Fired boiler 2004 Paprican, Montreal, Canada 8%vol 75% Coal fired Boiler 2004 Pulp Mill Boiler, US 11.5%vol 65% Coal fired Power Plant July Sept 2006 Saskpower, Poplar River, Canada 12% vol 90% Blast Furnace April Japan 22% vol 90% Natural Gas Fired Boiler May - Sept 2007 Shell-Statoil, Norway 4.5%vol 85% Cement Kiln 2008 North America 20%vol 90% and 45% More than 6,000 hours of piloting Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

7 Cansolv SO2 - CO2 Capture Integrated Flowsheet Treated Gas to Stack Condensate CO 2 Regenerator CO 2 Product Impurities ABSORPTION COLUMN CO 2 AMINE PURIFICATION UNIT Water Wash Steam Feed Gas In Line Quench Impurities Condensate SO 2 LEGEND SO 2 AMINE PURIFICATION UNIT SO 2 Regenerator Gas Phase Liquid Phase SO 2 Amine Make-up Water Steam CO 2 Amine Condensate Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

8 Cansolv Large Scale Carbon Capture Project Project: Integrated Carbon Capture and Sequestration (ICCS) Project Boundary Dam, Canada Client: SaskPower Corporation Project Outline: Flue gas CO 2 and SO 2 flue gas capture from Unit#3 (150 MW) of the BoundaryDam Power plant Capture capacity of 3,500 metric tons/day CO 2 CO 2 use: Enhanced Oil Recovery SO 2 converted to sulfuric acid Scope of Services: Front End Engineering Design phase (FEED), Engineering Procurement Construction (EPC), Commissioning, Operator Training Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

9 Presentation Outline CANSOLV Technologies and Commercial Experience Demonstration Plant Development of New Solvents for CO2 Capture Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

10 SO2 & CO2 Capture Demonstration Plant CO 2 absorber 36m CO 2 Regenerator SO 2 absorber SO 2 absorber Client: RWE Npower, UK Site: Aberthaw Coal Fired Power Station SO 2 Regenerator Pre-wash Capacity: 50 ton/day CO 2 capture Fluegas: 12 % vol CO 2 1,000 ppmv SO 2 Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

11 RWE Demonstration Plant Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

12 Elements of Demo Plant R&D Program Validation of Process design with Lean flash MVR heat integration Measuring heat / materials balance and effect of flue gas properties Impact of flue gas conditions and plant load on CO 2 capture performance and flexibility (deliberate start and stop cycles) Long-term solvent and materials performance Assessment of process environmental performance Solvents: CANSOLV DC New Generation Solvents Two years R&D program Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

13 Presentation Outline CANSOLV Technologies and Commercial Experience Demonstration Plant Development of New Solvents for CO2 Capture Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

14 Development of New Solvents for CO 2 Capture Technical Objectives Business Value 30% more CO2 loading in the solvent Reduced CAPEX Reduced space requirements Less inventory 25% less steam requirement Reduced operating costs Improved avoided CO2 figure in CO2 capture projects Increased solvent stability Reducing solvent loss and make-up rate Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

15 Solvents Screening on Loading & Stripping Setup Preliminary Screening Tool Evaluate the rich loading (or CO2 pick-up) Evaluate the lean loading (or ease of regeneration) Variable CO2 % in the inlet gas Alternative use: Degradation experiments Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

16 g CO2 / L solvent Solvents Screening on Loading & Stripping Setup Delta Loadings (on AVU unit - Solvent Comparison at 2.5 M) Suitable candidates identified to meet 30% more loading target Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

17 Screening New CO2 Solvents - Laboratory Pilot Unit Variation in packing height Intercooling Split flow Integrated data acquisition Fully automated 2m Accurate evaluation of regeneration duty and mass transfer phenomena Relative numbers for heat of regeneration Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

18 Stripping Factor (MJ/kg CO2) Solvent Screening on Laboratory Pilot Unit 5.50 Stripping Factor versus L/G 30wt% MEA 5.00 Formulation Formulation 7 Formulation 1 DC103 Formulation L/G (L/Nm3) Laboratory Pilot : relative energy requirements Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

19 Solvent Screening on Laboratory Pilot Unit Solvent L/G (L/Nm 3 ) Lean loading (mol/mol) Gas side delta loading (mol/mol) Stripping factor (MJ/kg CO 2 ) 30 wt% MEA Improvement over MEA (%) Formulation % Formulation % Formulation % Formulation % Formulation % Formulation % Formulation % Suitable candidates identified to meet 25% less steam target New candidates to be tested in 50 ton/day Demo plant Copyright of Royal Dutch Shell plc TAMQU CC Workshop April

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